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Concrete grinding

Workbook

Name:

Supporting:

LMFFL2107A: Select, operate

and maintain grinding

equipment

Concrete grinding – Workbook

Concrete grinding

Workbook

Containing learning activities and assignments for the unit of competency:

LMFFL2107A: Select, operate and maintain grinding equipment

The assignment templates are also available in an electronic ‘Word’ version, downloadable from the Flooring technology website at:www.flooringtech.com.au

Developed by Workspace Training for the 2012-2013Workplace English Language and Literacy (WELL) Program

Flooring Technology resource development project

© Commonwealth of Australia 2013

http://www.flooringtech.com.au/


ISBN: 978-0-9873327-8-3

Funded under the Workplace English Language and Literacy Program by the Australian Government through the Department of Industry, Innovation, Climate Change, Science, Research and Tertiary Education


CC BY-NC-SA

This work is copyright. Except where otherwise indicated, and save for the Commonwealth Coat of Arms, the Department has applied the Creative Commons Attribution-Noncommercial-Share Alike 3.0 Australia Licence to this work.

The Department of Industry, Innovation, Climate Change, Science, Research and Tertiary Education must be attributed as the author of the Department’s copyright material.

As far as practicable, material for which the copyright is owned by a third party has been clearly labelled. The Department has made all reasonable efforts to ensure that this material has been reproduced in the print-based resources and accompanying website with the full consent of the copyright owners.

Requests and enquiries concerning the Department’s copyright material should be addressed to:

The Legal Branch Department of Industry, Innovation, Climate Change, Science, Research and Tertiary EducationGPO Box 9839 Canberra ACT 2601 Email: [email protected]

Questions about the design and content of the resource itself should be addressed to the project manager:

David McElvennyWorkspace TrainingPO Box 1954 Strawberry Hills, NSW, 2012 Email: [email protected]



Table of contentsIntroduction...............................................................................................................1

Part 1 Learning activities..........................................................................................3

Section 1: Principles of grinding..............................................................................5

Section 2: Practice of grinding................................................................................8

Part 2 Assignments.................................................................................................11

Assignment 1.........................................................................................................13

Assignment 2.........................................................................................................15

Practical demonstrations.......................................................................................17


Concrete grinding – Workbook 1

IntroductionConcrete grinding is a ‘learning unit’ from the Flooring Technology training resource. It supports the following competency from the Certificate III in Flooring Technology (LMF31208):

LMFFL2107A: Select, operate and maintain grinding equipment

To be assessed as competent, your assessor will use a range of methods to check your understanding of the concepts presented in the Learner guide for this unit and your practical ability to select, operate and maintain concrete grinding equipment.

These may include:

written assignments

practical demonstrations

on-the-job discussions about how you go about particular activities

learning activities undertaken while you’re progressing through the unit

examples of installations you have undertaken

log book or work diary.

Literacy, numeracy and computer skills

Literacy is the ability to read and write. To complete this qualification, you will need sufficient literacy skills to produce a range of workplace documents. You will also need the skills to be able to read and understand documents such as order forms, installation instructions, project briefs and safe operating procedures.

Numeracy is the ability to work with numbers. Flooring installers need to do lots of measure-ups and calculations, so there will be many opportunities for you to learn and practise your numeracy skills.

When it comes to completing the written assignments for this qualification, a certain level of literacy ability is required to read the questions and write down your answers. There will also be times when you are asked to generate documents on a computer.

Obviously, it’s important that you clearly understand what the assignment is asking you to do, and that your work is a good reflection of what you really know. So if you’re having trouble reading the questions, writing down your answers, or using certain computer programs, make sure you speak to your trainer before you hand the assignment in.

There are various ways your trainer can help you. For example, they may be able to ask the assignment questions verbally and help you to write down your answers.



They may also be able to show you sample answers to similar questions, which will let you look at the way they’re written and give you hints on how to write your own. You may also be allowed to do the assignment with the assistance of another person.

Applying for RPL

RPL stands for Recognition of Prior Learning. It is a form of assessment that acknowledges the skills and knowledge you have gained through:

on-the-job experience

formal training in other courses

life experience, through your hobbies or other outside activities.

If you believe that you are already competent in some or all of the skills covered in this unit, ask your assessor about how to apply for RPL.

Using this workbook

All of the lessons in the Learner guide for this unit have learning activities at the end. Their purpose is to provide discussion points and questions to help reinforce your understanding of the concepts being presented.

There are also a range of assignments, which appear at the end of each section. These are designed to test your knowledge of the subject matter and ability to submit written responses in an acceptable format.

This workbook reproduces all of the learning activities and assignments in a format that lets you handwrite your answers to the questions.

Note that your trainer may ask you to produce a computer-generated document for all of the formal assignments, either printed out in hard copy or submitted electronically. To do this, go to the website version of the unit and look for the Assignment link in each section. This will allow you to type your answers into the ‘Word’ document and then either print it out or email it direct to your trainer as an attachment.

You may also be asked to share your learning activity answers electronically, especially if you are undertaking this unit by distance learning and are linked up with fellow students in other locations. This might be done through group emails or via a social networking site such as Facebook. In these cases, you should use the website resource rather than this workbook.



Part 1Learning activities



Section 1: Principles of grindingMachines used to prepare concrete

Let’s say you had a subfloor with a heavy layer of laitance on the surface, and it was too deep to remove easily with a grinder. What machine would you choose to clean up the laitance before you finished the floor with a grinder?

State the name of the machine below and explain why you would choose it.

Machine name Why you would choose it

Concrete surface profiles

Have a close look at each of the CSP photos in the learner guide. From what you know about the different processes used to create these CSPs, what characteristics can you see that makes each one distinctive?

In particular, what is it about the surface texture of the following processes that makes that type of concrete removal distinctive: grinding (CSP 2), shotblasting (CSP 3 and 5) and scarifying (CSP 4, 6 and 9).

Process Surface texture characteristics that make it distinctive

Grinding

Shotblasting

Scarifying



Types of grinders

The video clip below demonstrates the action of a counter-rotating planetary grinder:

‘Planetary Pro Genie’: http://www.youtube.com/watch?v=IzGezzfuPuM

Watch the video and answer the following questions:

1. How many diamonds does this three-headed machine hold?

2. How is the tooling secured to the grinding discs?

Now go to the following webpage and select the second video clip in the first column - called: ‘Each HTC Greyline grinder presented’.

http://www.htc-floorsystems.com/en/Common/Media/Videos.aspx#section2

Watch the video and answer the following questions:

3. What type of grinder is the first machine? (That is, describe its head configuration.) What is its grinding width?

Type of grinder

Grinding width

4. What type of grinder is the last machine? What is its grinding width?

Type of grinder

Grinding width


http://www.htc-floorsystems.com/en/Common/Media/Videos.aspx#section2

http://www.youtube.com/watch?v=IzGezzfuPuM


Diamond tooling

Watch the following video clip produced by Worx+:

‘Worx+ Diamond tools – Thick epoxy and levelling compound removal’:

http://www.youtube.com/watch?v=E_gPdd5zqY0

Then go to the following webpage to see the different types of diamond segments available for grinding (use the subcategories or filter buttons in the left hand menu):

http://www.totallyworks.com/products/categories/diamond-tools

Now have a look at some of the other types of diamond tooling by going to the All Preparation Equipment site at:

http://archquip.com.au/

Click on the menu link ‘Diamond tooling’ (in the top line of links) to see the range of products available.

Name three different types of tooling suitable for concrete grinding.

1.

2.

3.


http://archquip.com.au/

http://www.totallyworks.com/products/categories/diamond-tools

http://www.youtube.com/watch?v=E_gPdd5zqY0


Section 2: Practice of grindingHealth and safety

1. Are you required to complete a risk assessment or other type of safety document before you start work on-site?

2. What are the forms called, and what is their purpose?

Selecting the tooling

On the following page is an excerpt from a diamond selection table published in a Husqvarna operator’s manual. Use the table to answer the following questions:

1. What is the suggested tooling and set-up for flattening undulations in medium concrete?

2. What is the suggested tooling and set-up for removing vinyl or carpet glue in medium concrete?

3. Why are these recommendations different? Explain the reasons for the different choices in grit size and set-up (that is, full set or half set of diamonds)

Reasons for different grit sizes

Reasons for full set or half set of diamonds



Sample diamond selection table

Application Metal bond Grit size Full set Half set

Flatten undulations – hard concrete SOFT 16 or 30

Flatten undulations – medium concrete MEDIUM 16 or 30

Flatten undulations – soft concrete HARD 16 or 30

Vinyl or carpet glue removal – hard concrete SOFT 16 or 30

Vinyl or carpet glue removal – medium concrete MEDIUM 6 or 16

Vinyl or carpet glue removal – soft concrete HARD 6 or 16

Epoxy paint removal – hard concrete SOFT 6, 16 or 30

Epoxy paint removal – medium concrete MEDIUM 6, 16 or 30

Epoxy paint removal – soft concrete HARD 6, 16 or 30

Ceramic tile adhesive removal HARD 6, 16 or 30

Rain damaged concrete HARD 16 or 30

Operating procedures

Watch the following two video clips and then answer the questions below.

‘Husqvarna PG 280 and DC 1400 - Grinding a concrete floor’:

http://www.youtube.com/watch?v=Z7wm_zbS8d8&feature=player_detailpage

1. How are the diamond segments attached to the disc?

2. What sort of movement does the operator use while he’s grinding the floor? That is, what pattern is the machine being moved in?



‘Husqvarna PG 820 and PG 680’:

http://www.youtube.com/watch?v=jCyoTdIoVHA

3. What type of machine is the operator using?

4. What sort of movement does the operator use when he grinds the floor on the first pass? That is, what pattern is he moving the machine in?

Basic maintenance

1. Does your company have a maintenance checklist that you need to complete before operating a grinding machine? (Note that it may be called a different name or be built into another form, such as an SOP or pre-start checklist.)

2. What maintenance procedures are you responsible for? List the procedures and state how often you’re required to carry them out.

Maintenance procedure Frequency


http://www.youtube.com/watch?v=jCyoTdIoVHA


Part 2Assignments



Assignment 1

Name Date

1. What does ‘diamond grinding’ mean? That is, how are the diamonds used and what is their purpose?

2. What are the main advantages of using a concrete grinder, compared with other surface preparation machines?

3. (a) What does CSP stand for?

(b) What CSP can a diamond grinder achieve?

4. Circle the correct word in each of the following sentences:

If the concrete is hard – use a hard / soft bond segment

If the concrete is soft – use a hard / soft segment.



5. (a) If you found that the diamond segments had glazed over and become very hot, what would that tell you about your choice of bond hardness?

(b) What bond hardness would you fit to the machine to overcome the problem?



Assignment 2

Name Date

The questions below relate to the planetary action grinder that you’ll use for your practical demonstration. You should complete this assignment after you’ve selected the specific machine you plan to use.

1. Answer the following questions in the table below:

(a) Who is the manufacturer, what model is it, and how would you describe it?

(b) What voltage and amperage does it draw?

(c) What is the machine’s grinding width?

Manufacturer

Model

Grinder type

Voltage / amperage

Grinding width

2. Complete the following table to show the diamond tooling and disc set-up you would choose for each of the four different grinding applications.

ApplicationDiamond tooling

Bond Grit size Full set Half set

Smooth and remove high spots in hard concrete

Smooth and remove high spots in soft concrete

Remove old carpet adhesive in medium concrete

Smooth rain damaged concrete surface



3. Complete the following tables to show the operator maintenance you should carry out at various times on the grinding machine and dust extraction system.

Grinding machine

Frequency Operator maintenance

Daily (or before each use)

Weekly (or at regular intervals)

Every few months (or periodically)

Dust extraction system

Frequency Operator maintenance

Daily (or before each use)

Weekly (or at regular intervals)

Every few months (or periodically)



Practical demonstrationsYour trainer may ask you to keep a log book or diary of the work you do on-the-job that relates to the practical components of this unit. This will help them to determine when you’ve had sufficient hands-on practice in these tasks to undertake the assessment events.

When you’re ready to be assessed, your assessor will ask you to complete a range of practical demonstrations, including:

smoothing a concrete subfloor using single headed, double headed and planetary action grinders

completing operator maintenance on the grinding equipment.

Your assessor will also check that you can:

follow all work, health and safety requirements and environmental care procedures

use good manual handling practices

correctly interpret company documents and work instructions

communicate and work effectively with others

prevent damage to goods, equipment and products

work productively and produce a high quality job

modify activities and techniques used to suit different sites and working conditions.

Make sure you talk to your trainer or supervisor about any of the details you don’t understand, or aren’t ready to demonstrate, before the assessment events are organised. This will give you time to get the hang of the tasks you’ll need to perform, so that you’ll feel more confident when the time comes to be assessed.


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